Migrating Your Legacy DCS to PlantPAx
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1 CO900H 1 Migrating Your Legacy DCS to PlantPAx PUBLIC
2 Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. 2 PLANT-WIDE Control and Optimization SCALABLE and Modular SECURE Open and Information-enabled FLEXIBLE Delivery and Support
3 3 Agenda Recognize these challenges? Phased, Vertical, or Rip and Replace Migration Methods Migration Tools Reduce Risk and Cost Success Stories How We Can Help
4 4 Your Challenges? Financial Justification Typical Total Life-cycle Costs HW, SW, Networks (multi-systems PLC, Drives, DCS) Engineering Simulation Commissioning/Decommissioning Support contracts Energy Spare Parts (multi- systems) Floor Space Training - Operator, Maint, IT Upgrade, Expansion Off-spec product EPA Compliance Un-planned downtime Obsolescence Planning Consulting Benefits of a DCS Migration Enhanced Optimization capabilities Reduced life-cycle costs Increase yield and quality Decrease product variability Digital Bus Enabled More data faster decision making Easier integration with 3rd party (OEMs, ERP, MES, etc) PWC Scalable (10 to 10K I/O) Integrated Power End-users require high value upgrades to help justify a DCS migration
5 5 Industries where we serve Metals Water/Wastewater Mining Specialty Chemical Power Oil & Gas
6 6 Agenda Legacy DCS Market Outlook Phased, Vertical, or Rip and Replace Migration Methods Migration Tools Reduce Risk and Cost Success Stories How We Can Help
7 7 Legacy DCS Migration WHAT WE NEED FROM YOU EXPORTED CONSOLE DATABASE.dbf,.txt,.csv, or other files HARDCOPY PRINTOUTS of the legacy graphics / controller configuration ACTUAL I/O COUNTS and I/O Module types EXISTING LOOP DESCRIPTIONS and existing loop / P&ID drawings
8 8 Legacy DCS Migration WHAT WE NEED FROM YOU through interviews OPERATORS for their opinions and comments on current system operation and how they control their processes SYSTEMS/PLANT ENGINEERING to understand what they expect from their new process automation system MAINTENANCE PERSONNEL to understand how they troubleshoot and maintain the current system PLANT MANAGERS to understand their production schedules, challenges and how PlantPAx can improve production
9 9 Bailey Net90 / Infi90 Existing Architecture OIS Op Station 1 Bailey EWS OIS Op Station 2 CIU CIU CIU Plant Loop or Infi Loop PCU 1 PCU 2 TU TU
10 10 Bailey Net90 / Infi90 Migration Phase 1 Op Station 1 PAx EWS Redundant Servers Op Station 2 Ethernet Bailey Gateway OIS Op Station1 Bailey EWS OIS Op Station2 CIU CIU CIU Plant Loop or Infi Loop PCU 1 PCU 2 TU TU
11 11 Bailey Net90 / Infi90 Migration Phase 2 Op Station 1 PAx EWS Redundant Servers Op Station 2 Ethernet Bailey Gateway Bailey EWS CIU CIU Plant Loop or Infi Loop CLX 1 PCU 1 PCU 2 TU TU
12 12 Bailey Net90 / Infi90 Migration Phase 3 Op Station 1 PAx EWS Redundant Servers Op Station 2 Ethernet Bailey Gateway Bailey EWS CIU CIU Plant Loop or Infi Loop CLX 1 PCU 2 CLX 2 TU TU
13 13 Bailey Net90 / Infi90 Vertical Migration Op Station 1 PAx EWS Redundant Servers Ethernet Bailey Gateway OIS Op Station1 Bailey EWS OIS Op Station2 CIU CIU CIU CIU Plant Loop or Infi Loop CLX 1 PCU 1 PCU 2 TU TU
14 14 Rip and Replace of a Foxboro I/A DCS WP51 Console 1 WP51 Console 2 AW51 EWS Op Station 1 PAx EWS Redundant Servers Op Station 2 CP30/40/60 Ethernet Nodebus CP30/40/60 CLX 1 Fieldbus CLX 2 FBM s FBM s
15 15 Comparison of the Conversion Strategies Financial Justification Phased Rip and Replace Does not require shutdown for HMI replacement Can be funded with maintenance $ Is considered low risk to customer Can take multiple years to migrate entire system (higher TCO) Requires more legacy DCS expertise for delivery engineering team Can be easily switched back to the legacy system as part of a contingency plan Does require extended shutdown for entire project Requires capital expense $ approval (full system) Can be funded with maintenance $ (vertical slice or by area) Is considered high risk to customer Can replace entire system in weeks (lower TCO) Requires less legacy DCS expertise for delivery engineering team Cannot be easily switched back to legacy system
16 16 Agenda Recognize these challenges? Phased, Vertical, or Rip and Replace Migration Methods Migration Tools Reduce Risk and Cost Success Stories How We Can Help
17 17 Legacy Process Control System Migration and Conversion Solutions OPC Server Software Database Conversion Tool Custom Cable Solutions Engineered Interface (SAM) Dedicated Interface I/O Scanner Module Conversion Services Bailey NET90/INFI90 YES YES YES YES YES NO YES Honeywell TDC/TPS YES YES YES NO YES NO YES Honeywell IPC NO PARTNER YES NO NO YES YES Fisher PROVOX YES YES YES YES NO YES YES Moore APACS YES YES YES YES NO YES YES Rosemount RS3 YES PARTNER YES YES NO NO YES Foxboro I/A YES YES YES YES NO NO YES Westinghouse WDPF NO PARTNER YES NO NO NO YES Taylor MOD300 NO SSB YES NO NO TRIO I/O YES Emerson DeltaV YES SSB NO YES NO NO YES Yokogawa mxl YES NO NO YES NO NO YES Others N/A N/A N/A N/A N/A N/A YES
18 18 OPC Servers Commercially available Field proven For use in architectures using Whitebox PCs, or SAMs (PC in a CLX rack) Can be loaded directly on Factory Talk View Server
19 19 Integrated Gateway Solutions HDL Ethernet PROVOX Data Highway Benefits Peer-to-peer communication Increases performance Same environmental specs as ControlLogix system ControlLogix controller is data repository Integrated solution Optimized data server
20 20 Dedicated Interface for Bailey RA56-cATM-BLY90 Serial CIU/ICI Bailey Plant Loop Benefits Peer-to-peer communication Increases performance Same environmental specs as ControlLogix system ControlLogix controller is data repository Data is native to FactoryTalk applications Integrated solution Optimized data server
21 21 Dedicated Interface for Honeywell UCN SX101UCN Ethernet UCN network SX010UCN Benefits Peer-to-peer communication Increases performance ControlLogix controller is data repository Data is native to FactoryTalk applications Integrated solution No Honeywell equipment required Connects directly to UCN network
22 22 Dedicated Interface for Honeywell LCN SX009 (coming soon) Ethernet LCN network SX009 Benefits Peer-to-peer communication Increases performance ControlLogix controller is data repository Data is native to FactoryTalk applications Integrated solution Optimized data server No Honeywell equipment required Connects directly to LCN network
23 23 Database Conversion Tools Converts Legacy DCS DB tags to FactoryTalk View OPC tags or ControlLogix tags Used in conjunction with OPC Servers, (whitebox) PC s, or the Softing SAM
24 24 PROVOX I/O Scanner CLX-PVX module from ProSoft PROVOX Serial I/O network PROVOX Series10 or Series20 I/O Includes SMART I/O Benefits Operates in two modes shadow and scanner Retains legacy I/O significantly reducing front-end migration costs Fast and row risk legacy controller cutover Can be deployed in redundant configurations Supported by Rockwell Automation s Tech Connect
25 25 APACS I/O Scanner CLX-APX module from ProSoft I/O Bus Remote Modulrac Benefits Operates in two modes shadow and scanner Retains legacy I/O significantly reducing front-end migration costs Fast and row risk legacy controller cutover Can be deployed in redundant configurations Supported by Rockwell Automation s Tech Connect
26 26 Custom Cable Solutions Bailey
27 27 Custom Cable Solutions Foxboro IA
28 28 Agenda Legacy DCS Market Outlook Migration Tools Reduce Risk and Cost Phased, Vertical, or Rip and Replace Migration Methods Success Stories How We Can Help
29 29 Customer & Project Profile Warwick Chemical: Global market leader in the manufacture and supply of bleach activators for the detergent and biocides industries. Supply 60 countries in 5 continents What to Migrate? Fisher-Rosemount RS3 DCS installed at the site between 1994 an 2001, by 2013 will attain the status of Obsolete Business Drivers to change Obsolete Technology Platform Improve support and reduce costs Future plans for Process improvements at site Desire for single platform from a supportability Point of View It has to be said that Rockwell were not initially considered as a potential vendor for the DCS replacement and it was a discussion that I had with the Account Manager that started the ball rolling, so in that sense PlantPAx was an outsider. Which underlines the strength of the offering and the open nature of the assessment process
30 30 Global Solutions delivered migration Irish based alcoholic drink producer stated project was 100% Emerson Application focussed on Delta V PlantPAx capability overviewed as an alternative PlantPAx gave a better solution in Technical, Size and Life Cycle Costs PlantPAx was selected over Delta V RA responsiveness and attention to need made the difference
31 Global Solutions delivered migration UK sugar producer Dominant Honeywell site with 40,000 I/O on TDC/Experion High Life Cycle Costs TDC obsolescence forced review of batching processes Rockwell Automation LSBM benchmarked against Honeywell Rockwell Automation solution more advanced than Honeywell Rockwell Automation Migration Proposal and Life Cycle Options selected Multi site OEE in progress PUBLIC 31
32 Customer & Project Profile CLT Portugal (Companhia Logistica Terminais Maritimos) Deep Water Sea Port for Oil Storage & Logistic Operations Supply 100% Crude to Sines Refinery able to refine 220K Barres/day Used to export Oil Products (Fuel Oil, Diesel, Gasoline, Naphtha, ) What to Migrate? Honeywell TDC-3000, Based on distributed IPC-620 Controllers and I/Os Why to Migrate? Obsolete system not easier to find spare parts and very expensive High maintenance cost in service contracts Provide flexibility to change operations for new demanding needs and regulations New License requirements Main Challenges? Demonstrate superior value than existing 20+ year partner Keep existing communication structure to maintain terminal operation Reduce Customer Risk Shutdown, Downtime, Rockwell Automation Capabilities PUBLIC 32
33 33 Agenda Legacy DCS Market Outlook Migration Tools Reduce Risk and Cost Phased, Vertical, or Rip and Replace Migration Methods Success Stories How We Can Help
34 34 Global Process Tech Consultants (GPTC s) LARGE END USERS Consult work with corporate engineers to establish standard for operations SOLUTION PROVIDER Train on the best practices of using PlantPAx PROCESS OEMS Work with the OEM to re-write their application on a Rockwell Platform A&E Develop specifications for firms to establish Rockwell s platform Help define how we can migrate from legacy DCS to PlantPAx Partner with right delivery partners to assist in the technology adoption of Rockwell Automation s process control to the application Support across global regions to assist in project implementation (A&E, contractor, SI, and end user)
35 Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. 35 Global Process Tech Consultants (GPTC s) Process Control System Experts
36 36 Bringing You a World of Experience Helping you exceed your business goals Solutions 1 Manage projects that span multiple geographies Standard business & project processes The right team for your project from our worldwide talent Combining Technology & Application Knowledge All Major Industries Best Practices From Multiple Industries Based on PMI PMBOK Certified Project Managers Repeatable, measurable, auditable Risk Management Information Process Discrete Automation Power & Motion Sustainable Production Technology Migration Hardware Integration 80 Countries 20 Languages employees Average 13+ Years Experience Single point of contact
37 37 Services & Support Global Support. Local Address. Peace of Mind. Your Investment MEET YOUR EVERYDAY TECHNICAL NEEDS Online & Phone Support Training Services OnSite Services Repair Services MAXIMIZE YOUR AUTOMATION INVESTMENT MRO Asset Management Safety Services Energy Services Network & Security Services Legacy System Migration Plans Legacy System Migration Turn-Key Projects MAXIMIZE Productivity OPTIMIZE Plant Assets IMPROVE Financial Performance 80 Countries 20 Languages 6 Remote Support Centers 10 Remanufacturing Depots 9 Exchange Hubs Average 13+ Years Experience
38 Who should you contact for help? PUBLIC 38
39 39 White Papers Published DCS Migration White Papers available on Literature Library > Support > Product Resources > Justification for a Legacy Control System Migration PROCES-WP005A-EN-P DCS Migration Strategy and Project Implementation PROCES-WP006A-EN-P Optimization after Migration PROCES-WP008A-EN-P
40 Questions? PUBLIC Connect with us. PUBLIC CO900G 40
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